Modular construction system and method

ABSTRACT

Structural insulated panel construction systems and techniques permitting simplified construction with pre-field-assembled components.

CLAIM OF PRIORITY

The following application claims priority to U.S. Provisional Patent Application No. 61/115,484, filed Nov. 17, 2008, the complete contents of which are hereby incorporated by reference.

BACKGROUND

1. Field of the Invention

The present disclosure relates generally to construction systems and buildings and more specifically to a modular construction system and method.

2. Background

Conventional stick framing construction is laden with construction hinges that are an integral part of framing techniques. Moreover, there are numerous structural problems associated with conventional stick-frame construction when stick-framed structures are subjected to severe loads.

Structural Insulated Panels (SIPs) and composite panels do not share the same structural characteristics as common framing. In general, SIPs possess superior vertical, lateral, axial, racking and torsional resistance properties over conventional 2×4/2×6 construction. Alternate construction systems/methods result in significantly better thermodynamic properties of the resulting structure. Moreover, using conventional stick-frame and SIP construction techniques elements that are structurally unnecessary in the final structure are introduced. Specifically, where modular construction techniques are used, marriage walls are introduced that are ultimately structurally necessary only for shipping purposes.

What is needed is a system and method of modular construction that produces a structure with superior thermodynamic, structural and/or architectural properties, and structural support elements for reducing materials and labor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an isomeric view of an embodiment of a structure assembled from SIP modules.

FIGS. 2A-2B depict cross-sectional views of an embodiment of a hinged wall assembly.

FIG. 3 depicts a cross-sectional view of an embodiment of a keyway wall joint.

FIGS. 4A-4B depict cross-sectional views of embodiments of floor-wall connections.

FIGS. 5A-5B depict front and side cross-sectional views, respectively, of another embodiment of a floor wall connection having a roller assembly.

FIGS. 5C-5E depict alternate embodiments of a roller assembly for use with a floor-wall connection.

FIGS. 6A-6C depict and embodiment and details of a corner connection system.

FIGS. 7A-7F depict embodiments and details of prefabricated wall, floor, and roof corner connections.

FIGS. 8A-8E depict an embodiment and details of a corner bracket system.

FIG. 9 depicts one embodiment of a structural connector system.

FIGS. 10A-10B depict another embodiment and details of a structural connector system.

FIGS. 11A-11B depict an embodiment and details of a structural butt joint.

FIGS. 12A-12B depict an embodiment and details of a non-structural butt joint.

FIGS. 13A-13B depict an embodiment of a hinged roof assembly.

FIG. 13C depicts an alternate embodiment of a rocker for use with a hinged roof assembly.

FIGS. 13D-13E depict an alternate embodiment and detail of a hinged roof assembly.

FIGS. 14A-14B depict an embodiment of a cased window frame.

FIGS. 15A-15B depict an embodiment of a cased window frame system.

FIGS. 16A-16B depict two embodiments of roof ridge connections.

FIGS. 17A-17D depict embodiments of roof valley connector beams.

FIG. 18 depicts an embodiment of a pre-fabricated eave finish.

FIGS. 19A-19B depict an embodiment of a pre-fabricated shear-type gable overhang.

FIG. 20 depicts an embodiment of a strengthened SIP edge.

FIGS. 21A-21C depict an embodiment of a vented ridge cap roof system to provide for solar heated air or free cooling.

FIG. 22 depicts an embodiment of a skylight system.

FIG. 23 depicts an embodiment of insulating SIP coating.

FIGS. 24A-E depict marriage wall embodiments.

FIGS. 25A-I depict components of one embodiment of a structural support system.

DETAILED DESCRIPTION FIG. 1

FIG. 1 depicts one embodiment of a structure 100 assembled using pre-fabricated structural insulated panel (SIP) 102 modules. A structure 100 can comprise: a hinged wall assembly 200; a keyway wall joint 300; a floor-wall connection 400 and/or 500; a corner connection 600; wall and roof corner assemblies 700; a corner bracket assembly 800; a structural connector system 900 and/or 1001; a structural butt joint 1101; a non-structural butt joint 1201; a hinged roof connection 1301; a cased window frame 1401 and/or cased window frame system 1501; a roof ridge connection 1601; a roof valley connector beam 1701; an eave finish 1801; a gable overhang 1901; a vented roof system 2101; and/or a skylight system 2201.

In the embodiment depicted, windows can be factory-installed such that little to no assembly is required at a building site. In other embodiments, windows can be installed on site.

FIG. 2

FIGS. 2A, 2B depict cross-section views of one embodiment of a hinged wall assembly 200. A structural insulated panel (SIP) 202 can comprise a sheet or block of SIP insulation 204 sandwiched between SIP sheathing 206. In the embodiment shown in FIG. 2, a first SIP 202 a can be coupled with a second SIP 202 b via a hinge mechanism 208. A hinge mechanism 208 can comprise a hinge 212 and at least one hinge plate 214, and can be coupled with first and second SIPs 202 a, 202 b via at least one hinge block 210.

A hinge plate 214 can be made of steel or other metal alloy, or any other known and/or convenient material or combination of materials. A hinge 212 can be a continuous type hinge, an intermittent hinge with respect to the length of a SIP, or any other known and/or convenient type of hinge 212. A hinge block 210 can be made of environmentally friendly and/or recycled materials, such as but not limited to: mixed fiberglass scrap; products made from recycled wood chips, shavings, sawdust, or other wood products; recycled mineral products; polyurethane foam; reprocessed refuse; or any other known and/or convenient material. In the embodiment shown in FIG. 2, a hinge block 210 has thermodynamic properties such that the R-value of a hinge block 210 coupled with a hinge mechanism 208 is greater than or equal to the R-value of the SIP 202 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a hinged wall assembly 200. In other embodiments, a hinge block 210 and/or hinge mechanism 208 can have any other known and/or convenient thermodynamic properties.

In use, a hinged wall assembly 200 can be shipped to a construction site partially preassembled and in an open position with first and second SIP 202 a, 202 b adjacent and parallel to each other, as shown in FIG. 2B. One or both surfaces of hinge blocks 210 can then be coated with adhesive 216, such as but not limited to: thermoset adhesive, gypsum adhesive, methacrylate, cyanocrylate, epoxy-based adhesive, polyurethane, impregnated resins, or any other known and/or convenient type of adhesive. A first SIP 202 a can be subsequently rotated about a hinge 212 to bring the exposed surfaces of hinge blocks 210 in contact with each other. Hinge blocks 210 can then be bonded to each other via adhesive 216. Finally, a seam plate 218 can be affixed over the non-hinged side of the resulting hinged wall assembly 200 to strengthen the assembly and/or improve aesthetics. A seam plate 218 can be made of steel, extruded aluminum, or any other known and/or convenient material. A seam plate 218 can be coupled with a hinged wall assembly 200 via adhesive, screws, nails, or any other known and/or convenient coupling method or mechanism. In other embodiments, a hinged wall assembly 200 can be shipped and used in any other known and/or convenient manner.

In the embodiment shown in FIGS. 2A, 2B, a hinged wall assembly 200 can be fabricated by machining one end of a SIP 202 such that it can receive a complementary hinge block 210. In some embodiments, a hinge block 210 and the machined end of a SIP 202 can be coupled by being forced together, resulting in an interference fit. In other embodiments, a hinge block 210 can be bonded to the machined end of a SIP 202 via thermoset adhesive, gypsum adhesive, methacrylate, cyanocrylate, epoxy-based adhesive, polyurethane, impregnated resins, or any other known and/or convenient type of adhesive. In yet other embodiments, a hinge block 210 and a SIP 202 can be coupled using nails, pins, screws, or any other known and/or convenient type of coupling method and/or mechanism.

Referring to FIG. 2A, a first hinge plate 214 of a hinge mechanism 208 can be coupled with an exterior surface of a first SIP 202 a-hinge block 210 combination. In other embodiments, a first hinge plate 214 can be coupled with an interior surface of a first SIP 202 a-hinge block 210 combination. A second hinge plate 214 of a hinge mechanism 208 can be coupled with a hinge block 210 prior to coupling a hinge block 210 with a second SIP 202 b. Each hinge plate 214 can be coupled with a hinge 212. In other embodiments, hinge plates 214 can be coupled with hinge blocks 210 and SIPs 202 a, 202 b in any other known and/or convenient manner.

FIG. 3

FIG. 3 depicts a cross-section view of one embodiment of a keyway wall joint 300. First and second SIPs 302 a and 302 b, each comprised of SIP insulation 304 sandwiched between SIP sheathing 306, can be coupled with insulating blocks 308. Insulating blocks 308 can each have a chamber 310 adapted to mate with a spline 312. In some embodiments, both an insulating block 308 and a spline 312 can span the length of a SIP 302. In other embodiments, an insulating block 308 can be segmented and intermittently coupled with a SIP 302, and/or a spline 312 can be segmented and intermittently coupled with a SIP 302. A keyway wall joint 300 can further comprise at least one seam plate 314. Adhesive 316 can also be applied to one or more surfaces of insulating blocks 308 such that a bond can be formed between insulating blocks 308.

An insulating block 308 can be made of recycled and/or environmentally friendly materials such as, but not limited to, those described above with respect to a hinge block 210. In the embodiment depicted in FIG. 3, an insulating block 308 has thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIP 302 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a keyway wall joint 300. In other embodiments, an insulating block 308 and/or keyway wall joint 300 can have any other known and/or convenient thermodynamic properties. Adhesive 316 can be chosen from the adhesives described above with respect to FIG. 2, or can be any other known and/or suitable type of bonding substance, method, or mechanism. A spline 312 can be galvanized steel, wood, ceramic, cement, or any other material of suitable strength and thermodynamic properties.

In some embodiments, an insulating block 308 can be factory-installed in each SIP 302 a, 302 b. In use, SIPs 302 a, 302 b can be transported to a construction site in separate pieces and subsequently coupled with each other on site. On site, a spline 312 can be placed in the chamber 310 of a second SIP 302 b. Additionally, adhesive 316 can be applied to the exposed surface of at least one insulating block 308. A first SIP 302 a can be subsequently placed over a second SIP 302 b such that a spline 312 can mate with a chamber 310 of the second SIP 302 b. Pressure can be applied to a second SIP 302 b so as to press together insulating blocks 308. SIPs 302 a, 302 b can thus be coupled with each other via insulating blocks 308, a spline 312, and/or adhesive 316. In other embodiments, insulating blocks 308, a spline 312, and adhesive 316 can be pre-assembled and subsequently coupled with SIPs 302 a and 302 b on site.

A wall joint 300 can be further reinforced and/or aesthetics can be improved by using at least one seam plate 314 affixed along at least one seam between SIPs 302 a, 302 b. A seam plate 314 can be made of steel, extruded aluminum, or any other known and/or convenient material. A seam plate 314 can be coupled with a keyway wall joint 300 via adhesive, screws, nails, or any other known and/or convenient coupling method or mechanism. In other embodiments, a keyway wall joint 300 can be shipped and/or constructed in any other known and/or convenient manner.

In the embodiment shown in FIG. 3, a keyway wall joint 300 can be fabricated by machining one end of a SIP 302 such that it can receive a complementary insulating block 308. In some embodiments, an insulating block 308 can the machined end of a SIP 302 can be coupled by being forced together, resulting in an interference fit. In other embodiments, an insulating block 308 can be bonded to the machined end of a SIP 302 via thermoset adhesive, gypsum adhesive, methacrylate, cyanocrylate, epoxy-based adhesive, polyurethane, impregnated resins, or any other known and/or convenient type of adhesive. In yet other embodiments, an insulating block 308 and a SIP 302 can be coupled using nails, pins, screws, or any other known and/or convenient type of coupling method and/or mechanism.

FIG. 4

FIGS. 4A, 4B illustrate cross-sectional views of floor-wall connections 400. A foundation assembly 402 can comprise a foundation 404, sill plate 406, and sill seal 408 between a foundation 404 and sill plate 406. A foundation assembly 402 can further comprise an anchor assembly 410. An anchor assembly 410 can comprise a foundation anchor bolt 412 coupled with a female threaded coupler 414. A female threaded coupler 414 can run through a sill plate 406 and sill seal 408, as shown in FIG. 4.

A wall SIP 416 can be seated in a vertical position atop a sill plate 406 and can comprise a horizontal bottom plate 418 at one end. A bottom plate 418 can be coupled with a sill plate 406 and can comprise an aperture 420 through which a female threaded coupler 414 can be accessed. A floor SIP 422 can be perpendicularly coupled with a wall SIP 416 and can be at least partially seated on a foundation assembly 402. A floor SIP 422 can comprise a vertical perimeter plate 424 proximate to one end and coupled with a wall SIP 416. As shown in FIG. 4A, a perimeter plate 424 can be completely seated over a sill plate 406. In other embodiments, and as shown in FIG. 4B, a perimeter plate 424 can be partially seated over a sill plate 406. In other embodiments, a perimeter plate 424 can have any other known and/or convenient configuration with respect to a sill plate 406 and/or foundation assembly 402. A wall SIP 416 can further comprise an anchor access 426 through which a female threaded coupler 414 can be accessed. In other embodiments, a threaded coupler 414 can be a male threaded coupler.

A bottom plate 418 and/or a perimeter plate 424 can have thermodynamic properties such that the R-value of a plate 418 and/or 424 is greater than or equal to the R-value of the SIP 416 and/or 422 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a SIP 416/422 assembly. In other embodiments, SIPs 416 and/or 422 can have any other known and/or convenient thermodynamic properties.

In use, a wall SIP 416 and a floor SIP 422 can be shipped to a construction site as separate pieces or can be pre-assembled together. In some embodiments, a foundation assembly 402 can be factory-assembled. In other embodiments, the components of a foundation assembly 402 can be put together on site. Once a foundation assembly 402 is put in place on site, a wall SIP 416 (whether or not coupled with a floor SIP 422) can be positioned over a sill plate 406 such that a female threaded coupler 414 can be accessed through an aperture 420 in a bottom plate 418. Once these components are properly positioned, a screw or bolt can be coupled with a female threaded coupler 414 via an anchor access 426, thus securing a wall SIP 416 to a foundation assembly 402. Subsequently, a floor SIP 422 can be coupled with a wall SIP 416 and foundation assembly 402, if this step has not already been completed. In other embodiments, a floor-wall connection 400 can be assembled in any other known and/or convenient manner. In alternate embodiments, a male threaded coupler 414 can be coupled with a female member to secure a SIP to a foundation assembly 402.

FIG. 5

FIG. 5A depicts a front cross-sectional view of an alternate embodiment of a floor-wall connection 500. Multiple floor-wall connections 500 can be located throughout a foundation assembly 502. A foundation assembly 502 can comprise a foundation 504, sill plate 506, and sill seal 508. A foundation assembly 502 can further comprise an anchor bolt 510 coupled with a female threaded coupler 512. A female threaded coupler 512 can extend through a sill plate 506.

A wall SIP 514 can be seated in a vertical position atop a sill plate 506 and can comprise a horizontal bottom plate 516 at one end. A bottom plate 516 can be coupled with a sill plate 506 and can comprise an aperture 518 through which a female threaded coupler 512 can be accessed. A floor SIP 520 can be perpendicularly coupled with a wall SIP 514 and can be at least partially seated on a foundation assembly 502. A floor SIP 520 can comprise a vertical perimeter plate 522 proximate to one end and coupled with a wall SIP 514. As shown in FIG. 5, a perimeter plate 522 can be completely seated over a sill plate 506. In other embodiments, a perimeter plate 522 can be partially seated over a sill plate 506. In yet other embodiments, a perimeter plate 522 can have any other known and/or convenient configuration with respect to a sill plate 506 and/or a foundation assembly 502. A wall SIP 514 can further comprise an anchor access 524 through which a female threaded coupler 512 can be accessed. Additionally, at least one side of a foundation assembly 502 can be coupled with a joist hanger 526, and a joist hanger 526 can in turn be coupled with a floor joist 528. In other embodiments, SIPs 514 and 520 can be assembled in any other desired configuration.

A bottom plate 516 and/or a perimeter plate 522 can have thermodynamic properties such that the R-value of a plate 516 and/or 522 is greater than or equal to the R-value of the SIP 514 and/or 520 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a SIP 514/520 assembly. In other embodiments, SIPs 514 520 can have any other known and/or convenient thermodynamic properties.

A foundation assembly 502 can further comprise a roller assembly 530 adapted to allow SIPs 514 520 to be rolled onto a foundation assembly 502 and subsequently locked in place. A roller assembly 530 can comprise a channel 532 adapted to accommodate at least one wheel 534. A wheel 534 can be coupled with an axle pin 536 that can extend horizontally through a sill plate 506, such that a wheel 534 can turn about a horizontal axis. In the embodiment depicted in FIG. 5, an axle pin 536 has a tapered end and an exposed end. In other embodiments, an axle pin 536 can have any other known and/or convenient configuration or geometry. Multiple wheel 534/axle pin 536 assemblies can be spaced at regular or irregular intervals along a sill plate 506, depending on the physical properties of the load that they are intended to support.

An axle pin 536 can be positioned with respect to the vertical axis of a sill plate 506 such that the bottom of a wheel 534 can be raised a distance off the floor of a channel 532. In turn, the top of a wheel 534 can be raised above the top of a sill plate 506. The distance between a sill plate 506 and the top of a wheel 534 can be less than or equal to the distance between the bottom of the wheel 534 and the floor of a channel 532. Thus, when an axle pin 536 is removed from a sill plate 506, a wheel 534 can descend vertically in a channel 532 and the top of a wheel 534 can be flush with or lower than the surface of a sill plate 506.

In some embodiments, a SIP 514 and/or 522 can further comprise a roller plate 538. A roller plate 538 can be positioned such that SIPs 514 and 522 can be rolled over a wheel 534. A roller plate 538 can comprise a track such that the SIP load can be more easily guided over wheels 534. A roller plate 538 can be coupled with SIPs 514 and/or 522 via screws, pins, bolts, adhesive, or any other known and/or convenient type fastening or bonding method. In some embodiments, a roller plate 538 can be embedded into SIPs 514 and/or 522 such that its exposed surface is flush with that of SIPs 514 and/or 522.

In use, SIPs can be pre-assembled in any desired configuration prior to shipping to a construction site. A foundation assembly 502 can also be pre-assembled with the components described above. On site, a foundation assembly 502 can be secured in a desired location. Subsequently, SIPs 514 522 can be hoisted onto wheels 534 and rolled into place such that female threaded couplers 512 are in vertical alignment with and can be accessed through apertures 518. Once SIPs 514 522 are in place, axle pins 536 can be removed simultaneously, thus allowing wheels 534 to drop into channels 532. In turn, SIPs 514 522 can drop and come into contact with a foundation assembly 502. Anchor screws or bolts 540 can then be coupled with the appropriate female threaded couplers 512 via anchor access points 524 and apertures 518, thereby securing SIPs 514 522 to a foundation assembly 502.

FIG. 5B depicts a side cross-sectional view of a floor-wall assembly 500. In FIG. 5B, an anchor bolt 540 and female threaded coupler 512 are positioned behind a roller plate 538.

FIG. 5C depicts a top cross-sectional view of an alternate embodiment of a roller assembly 530. FIG. 5D depicts a front cross-sectional view of the roller assembly 530 depicted in FIG. 5C. FIG. 5E depicts a side cross-sectional view of the embodiment depicted in FIG. 5C. An axle 536 can be coupled with an axle channel 537. In contrast to the embodiment in FIG. 5A, an axle 536 in FIG. 5C may not be exposed at the exterior surface of a foundation 504.

The ends of an axle 536 can also be coupled with a pull-out mechanism 542 comprising two rod members 544 coupled with a handle bar 546. An axle 536 can be seated on the ends of rod members 544, as depicted in FIG. 5E, which can have a horizontal seat coupled with an angled end. Rod members 544 can be orthogonal to an axle 536 while a handle bar 546 can be parallel to an axle 536. Rod members 544 can extend through rod channels 548, and a handle bar 546 can be accessed from the exterior surface of a foundation 504, as shown.

In use, a floor and wall SIP 520 514 assembly can be hoisted onto a plurality of roller assemblies 530 coupled with a foundation 504. A SIP assembly can then be rolled into place in a manner similar to that described above with respect to FIG. 5A. Once SIPs 514 520 are in the correct position, a wheel 534 can be dropped into a channel 532 by using a handle bar 546 to pull rod members 544 out of a foundation 504 in a lateral direction. As shown in FIG. 5E, as rod members 544 are pulled out of a channel 532, an axle 536 can be guided down into a channel via the downward sloping ends of rod members 544. Upon complete removal of a pull-out mechanism 542 from a channel 532, wheels 534 can drop and SIPs 514 520 can subsequently drop onto a sill plate 506. In some embodiments, rod channels 548 can then be filled if desired.

FIG. 6

FIG. 6 depicts one embodiment of a corner connector 600 that can couple two SIPs 602 to form a corner. FIG. 6A illustrates a top cross-sectional view of a corner connector 600. FIG. 6B depicts a front planar view of an exterior corner reinforcement member 604. FIG. 6C depicts a front planar view of an interior corner reinforcement ember 606. A corner connector 600 can be used in horizontal or vertical corner applications.

A corner connector 600 can comprise an exterior reinforcement member 604 and at least one interior reinforcement member 606. An exterior reinforcement member 604 can comprise a perforated panel 608 flanked by dimpled side tabs 610. The perforations of a perforated panel 608 can facilitate strong bonding between the material of a corner connector 600 and a panel 608. Due to the dimples on side tabs 610, a side tab 610 can have a greater surface area to which adhesives can bond, when compared to a substantially planar piece of material. Thus, the bond between a SIP 602 and a tab 610 can be substantially increased. An interior reinforcement member 606 can also comprise a perforated panel 608 coupled with at least one dimpled side tab 610.

As depicted in FIG. 6A, a corner connector 600 can be prefabricated (by casting or other methods) such that an exterior reinforcement member 604 can be embedded proximate to the exterior surface 612 of a corner connector 600, and dimpled tabs 610 can extend beyond the SIP receiving edges 615 of a corner connector 600. At least one interior reinforcement member 606 can be coupled with the interior surface of a corner connector 600, and dimpled tabs 610 can extend beyond the SIP receiving edges 615 of a corner connector 600. Subsequently, SIPs 602 can be coupled with SIP receiving edges 615 such that outer surfaces of side tabs 610 can couple with the interior surfaces of SIP sheathing. This corner connector 600 assembly can be manufactured prior to transport to a construction site, such that minimal construction is needed on site. In other embodiments, a corner connector 600 can be fabricated in any other known and/or convenient manner and using any other known and/or convenient mechanisms.

In some embodiments, an interior reinforcement member 606 can have extension members 616 that can extend through the material of a corner connector 600, as illustrated in FIG. 6A. In the embodiment depicted in FIG. 6A, a corner connector 600 can comprise a core 618 made of insulating material. In other embodiments, a core 618 can increase the structural integrity of a corner connection 600. In yet other embodiments, a core 618 can comprise an air duct through which hot air can be carried to a roof ridge air duct 2102 (described below). In the embodiment shown in FIG. 6A, a corner connector 600 is shaped such that when it is coupled with SIPs 602, smooth corners can be formed. In other embodiments, a corner connector 600 can have any other known and/or convenient geometry.

SIPs 602 can be coupled with a corner connector 602 using adhesive chosen from those described above with respect to FIG. 2, or any other known and/or suitable type of bonding substance, method, or mechanism. A corner connector 600 can be substantially comprised of recycled and/or environmentally friendly materials such as, but not limited to, those described above with respect to a hinge block 210. In the embodiment depicted in FIG. 6, a corner connector 600 has thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIPs 602 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a corner connector 600/SIP 602 system. In other embodiments, a corner connector 600 and/or SIP 602 can have any other known and/or convenient thermodynamic properties.

FIG. 7

FIG. 7 depicts an embodiment of a wall and roof corner assembly 700. In the embodiment depicted in FIGS. 7A-7B, a one-piece F-shaped bracket 702 can be adapted to couple with the exterior surface of a corner formed by two SIPs 704. A bracket 702 can comprise a ridged portion 706 and two insertion members 708 extending there from. A first insertion member 708 a, extending from one side of a ridged portion 706, can be coupled with a substantially parallel first support panel 709 a. A second insertion member 708 b can be coupled with a substantially perpendicular second support panel 709 b.

In use, a bracket 702 can be coupled with the exterior surface of a corner formed by a first SIP 704 a and a second SIP 704 b such that: a ridged portion 706 can mate with the exposed insulation along the edge of a first SIP 704 a, substantially orthogonal to SIP 704 a sheathing; a first insertion member 708 a can be coupled with a first SIP 704 a, between SIP 704 a insulation and the exterior SIP 704 a sheathing; a second insertion member 708 b can be coupled with a first SIP 704 a, between SIP 704 a insulation and interior SIP 704 a sheathing; a first support panel 709 a can be coupled with and wrap around the outer surface of exterior SIP 704 a sheathing; and a second support panel 709 b can be coupled with the outer surface of the exterior sheathing on a second SIP 704 b.

FIG. 7C depicts an alternate embodiment of a corner assembly 700. A two-piece F-shaped bracket 710 can comprise a U-shaped ridged bracket 712 and a L-shaped compression plate 714. A U-shaped ridged bracket 712 can comprise a ridged portion 716 having two insertion members 718 extending from each end of a ridged portion 716. A ridged bracket 712 can be coupled with a first SIP 704 a by mating each insertion member 718 between the interior sheathing surface and insulation of a first SIP 704 a. In this embodiment, a ridged portion 716 can be pressed into or otherwise bonded with the exposed insulation along the edge of a first SIP 704 a. A compression plate 714 can subsequently be installed such that it can cover a ridged portion 716 and extend across at the exterior surfaces of first and second SIPs 704 a and 704 b at least partially.

In some embodiments, a ridged portion 706 or 716 can be pressed into the insulation along a standard SIP 704 a edge, while in other embodiments a SIP 704 a can be pre-machined to accept a ridged portion 706 or 716 and/or insertion members 708 or 718. In some embodiments, a bracket 702 or 712 and SIPs 704 can be pre-assembled such that minimal assembly is needed on site. In other embodiments, a bracket 702 or 712 can be installed on site. The length of insertion members 708 or 718, support panels 709, and/or a compression plate 714 can be application-specific, and can provide adequate support while minimizing thermal bridging between insertion members 708 or 718, support panels 709, a compression plate 714 and interior surfaces of a building.

A bracket 702 or 712 can be coupled with SIPs 704 via interference fit. In other embodiments, a bracket 702 or 712 can be coupled with SIPs 704 using adhesive chosen from those listed above with respect to FIG. 2, or any other known and/or convenient type of adhesive or method of chemical bonding. In yet other embodiments, a bracket 702 or 712 can be coupled with SIPs 704 using screws, nails, or any other known and/or convenient mechanical fastening mechanism. As depicted in FIGS. 7E-7F, a bracket 702 or 712 and/or a compression plate 714 can comprise perforations 720. Perforations 720 can have differing diameters so as to accommodate multiple uses. Some perforations 720 can be adapted to accept screws, nails, or any other known and/or convenient type of fastener, while other perforations 720 can simply serve as pilot holes.

A bracket 702 and/or 712 and/or a compression plate 714 can be made of galvanized steel, extruded aluminum, or any other known and/or convenient material.

FIG. 8

FIG. 8A depicts one embodiment of a corner bracket 800 that can add strength and support to a corner formed by SIPs 801. A corner bracket can comprise a first support panel 802 coupled perpendicularly with a second support panel 804. Insertion members 806 can be coupled with a second support panel 802 and can extend in the direction of a first support panel 802. As depicted in FIG. 8C, a bracket 800 can be coupled with a building corner by mating insertion members 806 with the interior surface of SIP 801 sheathing, similar to the method described above with respect to FIG. 7. A first support member 802 can be coupled with the exterior surface of a first SIP 801 a, and a second support member 804 can be coupled with the end of a first SIP 801 a and the exterior surface of a second SIP 801 b.

As depicted in FIG. 8D, at least one insertion member 806 can have a substantially triangular shape to facilitate coupling with a SIP 801. In other embodiments, insertion members 806 can have any other known and/or convenient geometry. As depicted in FIGS. 8B, 8D, and 8E, support panels 802 and/or 804 can have perforations 808 that can be coupled with fasteners or can be used as pilot holes. In some embodiments, a bracket 800 can be coupled with a corner using adhesive or any other known and/or convenient type of bonding or fastening method or mechanism.

FIG. 9

FIG. 9A depicts a cross-sectional view of one embodiment of a structural connector system 900 that can be used in wall, floor, or roof applications, or any other suitable application. Two SIPs 902 can be coupled with a wall 904 in a T-shape connection via a connector beam 906 that can run along an edge of each SIP 902.

A connector beam 906 can be made of recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210. In the embodiment depicted in FIG. 9A, a connector beam 906 has thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIP 902 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a structural connector system 900. In other embodiments, a connector beam 906 and/or structural connector system 900 can have any other known and/or convenient thermodynamic properties.

A connector beam 906 can be reinforced by having at least one mesh structure 912 running through it in a longitudinal fashion. A mesh structure 912 can run through the entire length of a connector beam 906, or can have any other known and/or convenient length or geometry. A mesh structure 912 can be made of steel or any other material having suitable strength and thermodynamic properties.

A structural connector system 900 can be fabricated by machining one end of a first SIP 902 such that it can partially mate with a connector beam 906, as depicted in FIG. 9A. A connector beam 906 can mate with a first SIP 902 by pressing the two together to form an interference fit. In other embodiments, a connector beam 906 can be coupled with a SIP 902 using adhesive 908. Adhesive 908 can be chosen from the adhesives described above with respect to FIG. 2, or can be any other known and/or suitable type of bonding substance, method, or mechanism. A second SIP 902 can be subsequently coupled with the same connector beam 906 in a manner similar to that described above with respect to a first SIP 902. In the embodiment shown in FIG. 9A, edges of the sheathing of first and second SIPs 902 are not touching. In other embodiments, first and second SIPs 902 can be positioned in any other known and/or convenient configuration with respect to each other. A structural connector system 900 can be pre-assembled and subsequently shipped to a construction site such that minimal assembly is required on site.

A connector beam 906 can also be coupled with a wall 904 such that a wall 904 can be substantially perpendicular to SIPs 902. In the embodiment shown in FIG. 9A, a wall 904 is coupled with a connector beam 906 via two top plates 910. In other embodiments, a wall 904 and connector beam 906 can be coupled in any other known and/or convenient manner. In some embodiments, a single top plate 910 can be used. A connector beam 906 can be coupled with a wall 904 and/or top plates 910 using adhesive 908, screws, nails, or any other known and/or convenient method or type of mechanical or chemical coupling. A wall 904 can be a stud wall, an additional SIP, or any other known and/or convenient type of vertical structure or support.

FIG. 10

FIG. 10A depicts a cross-sectional view of an embodiment of a structural connector system 1001 that can be used in wall, floor, or roof applications, or any other suitable application. The ends of two SIPs 1002 can be coupled via a connector beam 1004 that can run along the connecting edge of each SIP 1002.

A connector beam 1004 can be made of recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210. In the embodiment depicted in FIG. 10A, a connector beam 1004 has thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIP 1002 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a structural connector system 1001. In other embodiments, a connector beam 1004 and/or structural connector system 1001 can have any other known and/or convenient thermodynamic properties.

A connector beam 1004 can be reinforced by having at least one mesh structure 1008 running through it in a longitudinal fashion, as shown in FIG. 10A. A planar view of a mesh structure 1008 is shown in FIG. 10B. A mesh structure 1008 can run through the entire length of a connector beam 1004, or can have any other known and/or convenient length or geometry. A mesh structure 1008 can be made of steel or any material of suitable strength and thermodynamic properties.

A structural connector system 1001 can be fabricated by machining one end of a first SIP 1002 such that it can at least partially mate with a connector beam 1004, as depicted in FIG. 10A. A connector beam 1004 can mate with a first SIP 1002 by pressing the two together to form an interference fit. In other embodiments, a connector beam 1004 can be coupled with a SIP 1002 using adhesive 1006. Adhesive 1006 can be chosen from the adhesives described above with respect to FIG. 2, or can be any other known and/or suitable type of bonding substance, method, or mechanism. A second SIP 1002 can be subsequently coupled with the same connector beam 1004 in a manner similar to that described above with respect to a first SIP 1002. In the embodiment shown in FIG. 10A, edges of the sheathing of first and second SIPs 1002 are touching. In other embodiments, first and second SIPs 1002 can be positioned in any other known and/or convenient configuration with respect to each other. A structural connector system 1001 can be pre-assembled and subsequently shipped to a construction site such that minimal assembly is required on site.

FIG. 11

FIG. 11A depicts one embodiment of a structural butt joint 1101. Two SIPs 1102 can be coupled via a coupling element 1104. A coupling element 1104 can have at least three channels 1105. Each channel 1105 can comprise two flange members 1106, as depicted in FIG. 11B, and each flange member 1106 can comprise a plurality of teeth 1108 along its interior edge. Teeth 1108 can assist in gripping the interior and exterior surfaces of SIP 1102 sheathing, thereby preventing slippage when in use. A coupling element 1104 can also be coupled with a support block 1110.

In the embodiment shown in FIGS. 11A and 11B, a coupling element 1104 can have a T-shape with three channels 1105—two horizontal channels 1105 and one vertical channel 1105. Referring to FIG. 11A, vertical channels 1105 of two coupling elements 1104 can be coupled with a support block 1110, whereby the flange members 1106 of each vertical channel 1105 can at least partially grip the ends of a support block 1110. Additionally, horizontal channels 1105 can engage the ends of SIPs 1102 as depicted. In this embodiment, a coupling element 1104 can act to transfer stress from flange members 1106 to a support block 1110.

A coupling element 1104 can be made of extruded aluminum or any other known and/or convenient material. A support block 1110 can be made of recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210. In the embodiment depicted in FIG. 11A, coupling element 1104 and/or support block 1110 can have thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIPs 1102 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a structural butt joint 1101. In other embodiments, a structural butt joint 1101 can have any other known and/or convenient thermodynamic properties. A structural butt joint 1101 can be pre-assembled and subsequently shipped to a construction site such that minimal assembly is required on site.

FIG. 12

FIG. 12A depicts one embodiment of a non-structural butt joint 1201. Two SIPs 1202 can be coupled via a coupling element 1204. A coupling element 1204 can have at least two channels 1205. Each channel 1205 can comprise two flange members 1206, as depicted in FIG. 12B, and each flange member 1206 can comprise a plurality of teeth 1208 along its interior edge. Teeth 1208 can assist in gripping the interior and exterior surfaces of SIP 1202 sheathing, thereby preventing slippage when in use.

In the embodiment shown in FIGS. 12A and 12B, a coupling element 1204 can have linear geometry with two channels 1205. Referring to FIG. 12A, channels 1205 can engage the ends of SIPs 1202 as depicted. In some embodiments, filler material 1210 can be applied between the ends of the SIPs 1202 that are coupled by a coupling element 1204.

A coupling element 1204 can be made of extruded aluminum or any other known and/or convenient material. A filler material 1210 can be insulating and can be foam, sealant, or recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210. In some embodiments, filler material 1210 can be a solid block or beam that can be factory-installed or installed on site. In the embodiment depicted in FIG. 12A, coupling element 1204 and/or filler material 1210 can have thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIPs 1202 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a non-structural butt joint 1201. In other embodiments, a non-structural butt joint 1201 can have any other known and/or convenient thermodynamic properties. A non-structural butt joint 1201 can be pre-assembled and subsequently shipped to a construction site such that minimal assembly is required on site.

FIG. 13

FIGS. 13A and 13B depicts one embodiment of a hinged roof connection 1301. A hinge assembly 1302 can be coupled with a roof SIP 1304 and a wall SIP 1306. A hinge assembly 1302 can comprise a hinge block 1308 coupled with a rocker 1310 at a pivot point 1312. A hinge block 1308 can be coupled with a wall SIP 1306, and a rocker 1310 can be coupled with a roof SIP 1304, as depicted in FIGS. 13A, 13B. A roof SIP 1304 can comprise an end cap 1305 proximate to the hinged end of a roof SIP 1304. An end cap 1305 can improve aesthetics, stiffen the end of a SIP 1304, and/or provide further insulation.

A hinge block 1308 and/or rocker 1310 can be made of wood, aluminum, steel, or recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210. In the embodiment depicted in FIG. 13, a hinge assembly 1302 can have thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIPs 1304 1306 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a hinged roof connection 1301. In other embodiments, a hinged roof connection 1301 can have any other known and/or convenient thermodynamic properties.

A hinge assembly 1302 and SIPs 1304 1306 can be coupled with each other prior to shipping and/or storage. In transit, a hinged roof connection 1301 can be configured such that SIPs 1304 1306 are substantially perpendicular, as shown in FIG. 13A. In other embodiments, a hinged roof connection 1301 can be shipped or stored in any other known and/or convenient configuration. A shipping screw 1314 can be run latitudinally through and proximate to an end of a roof SIP 1304, as shown in FIG. 13B. A shipping screw 1314 can have a length sufficient to extend through a roof SIP 1304 and into a hinge assembly 1302 such that when tightened it can restrict hinge assembly and SIP movement about a pivot point 1312.

A hinged roof connection 1301 can be substantially assembled prior to reaching a construction site. Once on site, a wall SIP 1306 can be erected and secured in an appropriate location. A shipping screw 1314 can then be loosened or removed and a roof SIP 1304 lifted and rotated about a pivot point 1312 until a desired pitch is reached. Once raised, a locking screw 1316 can be inserted through a roof SIP 1304. A locking screw 1316 can be substantially parallel to a shipping screw 1314 and can extend through a hinge assembly 1302 such that it can restrict hinge assembly and SIP movement, as depicted in FIG. 13B.

After lifting a roof SIP 1304 into a desired position, insulating material 1318 and fascia 1320 can be applied on site to complete assembly of a hinged roof connection 1301. Insulating material 1318 and/or fascia 1320 can be recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210.

FIG. 13C illustrates an alternate rocker 1310 configuration. A rocker 1310 can have an extended arm member 1322 such that it can couple latitudinally with the end of a roof SIP 1304 in lieu of an end cap 1305.

FIG. 13D illustrates an alternate embodiment of a hinged roof connection 1301 in which SIPs 1304 and 1306 each comprise complementary hinge components 1324 a and 1324 b that can rotate about a pivot point 1312. FIG. 13D depicts a cross-sectional view of a pivot point 1312. Hinge components 1324 a and 1324 b can further comprise complementary teeth 1326 a and 1326 b, respectively. These teeth components 1326 can prevent lateral movement of hinge components 1324 while still facilitating rotational movement about a pivot point 1312. SIPs 1304 and 1306 can also be coupled with an eave finish 1328.

FIG. 14

FIG. 14A depicts a side cross-sectional view of one embodiment of a cased window frame 1401 comprising a window opening 1402, upper SIP 1404, and lower SIP 1406. At least one casing 1408 can selectively engage upper and/or lower SIPs 1404 1406 to frame an opening 1402. A window opening 1402 can also comprise sidewall SIPs that can further comprise at least one casing 1408. As shown in FIG. 14B, which illustrates a close-up cross-section of a casing 1408, a casing 1408 can comprise a substantially planar member 1410 coupled with flange members 1412. Flange members 1412 can have beveled ends that can add to the structural integrity of casing-SIP connections. In some embodiments, a casing 1408 can be pressed into a SIP 1404 or 1406, forming an interference fit. In other embodiments, adhesive can be used to bond a casing 1408 to a SIP 1404 1406. In yet other embodiments, nails or screws can be used to couple a casing 1408 and a SIP 1404 or 1406. In alternate embodiments, any combination of the above methods can be used, and/or any other known and/or convenient method of coupling.

A casing 1408 can be made of wood, aluminum, steel, or recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210. In the embodiment depicted in FIG. 14A, a casing 1408 can have thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIPs 1404 1406 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a cased window frame 1401. In other embodiments, a cased window frame 1401 can have any other known and/or convenient thermodynamic properties.

FIG. 15

FIG. 15A depicts a side cross-sectional view of a cased window frame system 1501. FIG. 15B illustrates a front planar cross-sectional view of the cased window frame system 1501 of FIG. 15A. A cased window frame system 1501 can comprise a window opening 1502 and a window frame 1504. A window frame 1504 can comprise a header block 1506, header SIP 1508, lower SIP 1510, and casing 1512. A window frame 1504 can also comprise side SIPs 1516, as shown in FIG. 15B.

A header block 1506 can extend upwards through a header SIP 1508, as depicted in FIG. 15A, and can further comprise a wire meshwork 1514 for added strength and load capacity. Wire meshwork 1514 can span the entire length of a header SIP 1508, as shown in FIG. 15B. In other embodiments, a wire meshwork 1514 can have any other known and/or convenient configuration.

A single continuous casing 1512 can be selectively engaged with each of the interior faces of a window opening 1502 and can be supported by a header block 1506 and header SIP 1508. In other embodiments, a casing 1512 can have any other known and/or convenient geometry. A header block 1506 and casings 1512 can be coupled with SIPs 1508, 1510, and/or 1516 via interference fit, adhesive, nails or screws, or any other know and/or convenient type of chemical or mechanical bonding or fastening.

A casing 1512 and/or header block 1506 can be made of wood, aluminum, steel, or recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210. In the embodiment depicted in FIG. 15, a casing 1512 and/or header block 1506 can have thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIPs 1508, 1510, and/or 1516 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a cased window frame system 1501. In other embodiments, a cased window frame system 1501 can have any other known and/or convenient thermodynamic properties. A cased window frame system 1501 can be pre-assembled and subsequently shipped to a construction site such that minimal assembly is required on site.

FIG. 16

FIG. 16 depicts cross-sectional views of two embodiments of roof ridge connections 1601. In FIG. 16A, a non-vented roof ridge connection 1601 can comprise a ridge beam 1602, roof SIP 1604, and SIP end block 1606. A SIP end block 1606 can comprise an integrated hanger 1608, whereby the hanger 1608 has an exposed end for fastening to a ridge beam 1602. SIP 1604 can be coupled with a ridge beam 1602 such that the uppermost edge of a SIP 1604 can be proximately coupled with the uppermost edge of a ridge beam 1602, as depicted in FIG. 16A. The exposed end of a hanger 1608 can be bent such that it can couple with the top surface of a ridge beam 1602, and can be fastened to a ridge beam 1602 via a vertical fastener 1610. In the embodiment shown, a vertical fastener 1610 is a nail, but in other embodiments, a fastener 1610 can be a screw, pin, or any other known and/or convenient fastening mechanism. In other embodiments, a hanger 1608 can be a saddle hanger and can be fastened to the opposing face of a ridge beam 1602. In some embodiments, the connection between the end of a hanger 1608 and a ridge beam 1602 can be reinforced by using adhesive or any other known and/or convenient type of chemical bonding.

Referring to FIG. 16B, a vented rood ridge connection 1601 is depicted. In contrast to the non-vented connection in FIG. 16A, the uppermost edge of a roof SIP 1604 can be positioned below the top edge of a ridge beam 1602, such that the end of a hanger 1608 can be coupled with a side surface of a ridge beam 1602. In this embodiment, a hanger 1608 can be coupled with a ridge beam 1602 via a horizontal fastener 1610, as depicted. In other embodiments, a hanger 1608 can be a saddle hanger or can couple with the top surface of a ridge beam 1602. Additionally, a vented roof ridge connection 1601 can comprise a spacer 1612 positioned above and in parallel with a SIP 1604 such that airflow is permitted between a SIP 1604 and the spacer 1612.

In the embodiments shown, a ridge beam 1602 is made of wood. In other embodiments, a ridge beam 1602 can be made of any other known and/or convenient material. A SIP end block 1606 can be made of wood or recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210. A hanger 1608 can be made of extruded aluminum, steel, or any other known and/or convenient material. In the embodiment depicted in FIG. 16, a SIP end block 1602 can have thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIP 1604 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a ridge roof connection 1601. In other embodiments, a ridge roof connection 1601 can have any other known and/or convenient thermodynamic properties. A ridge roof connection 1601 can be pre-assembled and subsequently shipped to a construction site such that minimal assembly is required on site.

FIG. 17

FIGS. 17A-17D depicts several embodiments of a roof valley connector beam 1701. A valley connector beam 1701 comprising at least two anchor members 1703 can couple with at least two downward sloping roof or ceiling SIPs 1702. FIGS. 17A and 17B depict embodiments designed for vented roof systems. An upper extension member 1704 can have a vented portion 1706 and can terminate in a V-shaped channel 1708, thereby allowing water to collect in and run down a channel 1708 and preventing flooding of a vented portion 1706 during heavy rainfall. A vented portion 1706 can comprise water impermeable/gas transmissible material (such as, but not limited to, Tyvek®), wire mesh, or any other known and/or convenient type of vent that can allow air to pass through.

FIGS. 17C and 17D depict embodiments of connector beams 1701 designed for non-vented roof systems. A connector beam 1701 can have a channel 1710 that can be substantially flush with the upper surfaces of SIPs 1702. In the embodiment shown in FIG. 17C, a channel 1710 is V-shaped. In other embodiments, a channel 1710 can have any other known and/or convenient geometry.

FIGS. 17B and 17C depict embodiments of a valley connector beam 1701 having a lower extension member 1712 that can be coupled with a wall or other type of support within a building. In alternate embodiments, a lower extension member 1712 can be used for aesthetic appeal rather than coupling with a wall or support beam.

In some embodiments, a valley connector beam 1701 can have a wire truss running through in a longitudinal manner to add strength to the beam 1701. A connector beam 1701 can be made of wood or recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210. In the embodiments depicted in FIG. 17, a connector beam 1701 can have thermodynamic properties such that its R-value is greater than or equal to the R-value of the SIPs 1702 with which it is coupled. In some embodiments, the R-value can be substantially constant throughout a valley connector beam assembly. In other embodiments, a valley connector beam assembly can have any other known and/or convenient thermodynamic properties. A valley connector beam 1701 and SIPs 1702 can be pre-assembled and subsequently shipped to a construction site such that minimal assembly is required on site.

FIG. 18

FIG. 18 depicts one embodiment of a pre-fabricated eave finish 1801. An eave finish 1801 can comprise a gutter 1802, fascia 1804, a soffit vent 1806, and strengthening ribs 1808. Roof sheathing 1810 can be coupled with roof and wall SIPs 1812 and 1814, respectively, and at least one rafter 1818. A gutter 1802 and fascia 1804 can be coupled with each other and along the edge of roof sheathing 1810, and fascia 1804 can further comprise a drip edge 1816 to force adhering drops of water to fall free of the face of the building rather than run toward the interior. A soffit vent 1806 can allow air to flow into the space below roof sheathing 1810. A soffit vent 1806 can be coupled with at least two strengthening ribs 1808. In the embodiment depicted in FIG. 18, a horizontal rib 1808 is coupled with a substantially vertical, but slightly angled, rib 1808. In other embodiments, any other known and/or convenient type of configuration and/or quantity of strengthening ribs 1808 can be used.

The components of an eave finish 1801 can be made of extruded aluminum, metal alloys, or any other known and/or convenient material or combination of materials. An eave finish 1801 can be fabricated and assembled prior to shipping to a construction site, such that on site minimal assembly is required. In the embodiment depicted in FIG. 18, on site an eave finish 1801 can be coupled with roof sheathing 1810, a rafter 1818, and a wall SIP 1814 at connection points 1820, 1824, and 1826. These connections can be made using adhesive, screws, nails, or any other known and/or convenient type of fastener or bonding method.

FIG. 19

FIG. 19 depicts an embodiment of a gable overhang 1901 adapted to reduce structural damage under extreme loading conditions. A gable overhang 1901 can have a “ladder” configuration and can comprise an interior beam 1902 coupled with a building envelope 1905; an exterior beam 1904 that can be substantially parallel to an interior beam 1902; a roof deck 1906; and a soffit assembly 1908. An exterior beam 1904 can further comprise fascia 1910 and a flashing 1912 proximate to at least one beam joint. Beams 1902 and 1904 can be coupled with opposite edges of a roof deck 1906 and soffit assembly 1907, as depicted in FIG. 19B. Additionally, a building envelope 1905 can comprise a wall and/or roof SIP, and a gable overhang 1901 can be substantially flush with the upper surface of a building envelope 1905.

An interior beam 1902 can be coupled with a building envelope 1905 using nails or screws, as depicted in FIG. 19B. In other embodiments, adhesive or any other known and/or convenient type of bonding or fastening can be used. In some embodiments, a seam plate 1914 can be fastened over a gable overhang 1901/building envelope 1905 seam, thereby strengthening the connection between a gable overhang 1901 and building envelope 1905. A seam plate 1914 can be made of steel, aluminum, or any other known and/or convenient material. An interior beam 1902 and/or an exterior beam 1904 can be made of wood or any other known and/or convenient material suitable for withstanding severe weather conditions. In the embodiment depicted in FIG. 19B

FIG. 20

FIG. 20 depicts one embodiment of a strengthened SIP edge 2001. The interior side of sheathing 2004 of a SIP 2002 can be reinforced with steel or other metal plates 2006 proximate to an edge of a SIP 2002. Metal plates 2006 can be installed during manufacturing of a SIP 2002. In other embodiments, a prefabricated SIP 2002 can be machined such that plates 2006 can be slid into a SIP 2002 from an outside edge, such that plates 2006 can be sandwiched between SIP insulation 2008 and SIP sheathing 2004.

FIG. 21

FIG. 21 depicts an embodiment of a vented roof system 2101 that can run along the ridge of a roof, as depicted in FIG. 21C. A vented roof system 2101 can comprise an air duct 2102 coupled with base members 2104 extending from the lower half of an air duct 2102 and over each side of a roof. A hood 2106 comprising stamped louvers 2108 can cover an air duct 2102 and can shield an air duct 2102 from the elements.

A base member 2104 can comprise a splashguard 2110 and at least one drain hole 2112. An air duct 2102 can also comprise at least one condensate hole 2114 such that condensation can be drained. Drain holes 2112 and/or condensate holes 2114 can be spaced along a base member 2104 and/or air duct 2102 at equal intervals. In other embodiments, drain holes 2112 and/or condensate holes 2114 can be located at any other known and/or convenient locations along a base member 2104 and/or air duct 2102.

A base member 2104 can further comprise at least one filter 2116 that can be water impermeable/gas transmissible (such as, but not limited to, Tyvek®), thus allowing the free flow of air into or out of the space below an air duct 2102. In the embodiment depicted, warm or hot air emitted from a vented roof can heat the gases within an air duct 2102 by convection. In some embodiments, an air outlet 2118 can be coupled with a heat recovery ventilator or other apparatus at one end of an air duct 2102. In the embodiment depicted, a vented roof system 2101 can be assembled prior to shipping and affixed to a roof on site.

FIG. 22

FIG. 22 illustrates a cross-sectional view of one embodiment of a skylight system 2201. Ceiling or roof SIPs 2202 can be coupled with a skylight enclosure 2204. A skylight enclosure 2204 can comprise at least two mirrored members 2206 that can be angled, substantially parallel, and facing each other. In the embodiment shown, one mirrored member 2206 can face upwards, and another mirrored member 2206 can face downwards.

A skylight enclosure 2204 can further comprise at least two double pane windows 2208. In the embodiment shown, a first double pane window 2208 can be located above an upwards-facing mirrored member 2206 in a substantially horizontal configuration, and can be exposed to the outdoors. A second double pane window 2208 can be located below a downwards-facing mirrored member 2206 in a substantially horizontal configuration, and can be exposed to the interior of a building. Thus, light can be transmitted through a first double pane window 2208, reflect off an upwards-facing mirrored member 2206, hit a downwards-facing mirrored member 2206, and in turn be reflected through a second double pane window 2208 into a building.

In some embodiments, a third double pane window 2206 can be positioned vertically between mirrored members 2206, as depicted in FIG. 22. Additionally, insulating material 2210 can fill the space between the non-reflective surfaces of mirrored members 2006 and an enclosure 2204.

A skylight enclosure 2204 can be made of extruded aluminum, or any other known and/or convenient material or combination of materials. Insulating material 2210 can be recycled and/or environmentally friendly material such as, but not limited to, those described above with respect to a hinge block 210.

In the embodiment shown in FIG. 22, a skylight system 2201 can be pre-assembled prior to arriving at a construction site. Therefore, on site, the entire system 2201 including surrounding SIPs 2202 can simply be coupled with the rest of a roofing and/or ceiling assembly during the construction process. In other embodiments, a skylight system 2201 can be pre-assembled except for SIPs 2202, which can be pre-cut but coupled with an enclosure 2204 on site. In yet other embodiments, insulating material 2210 can be installed on site. In alternate embodiments, a skylight system 2201 can be assembled in any other known and/or convenient manner, order, or place.

FIG. 23

FIG. 23 depicts a cross-sectional view of one embodiment of a SIP 2302 and SIP coating 2304. Section 2306 illustrates an uncoated section of a SIP 2302. Section 2308 depicts a portion of a SIP 2302 covered with a SIP coating 2304. A SIP coating 2304 can possess low permeability properties, have high termite protection properties due to reduced moisture content, can be chemically treated with a non-toxic substance that can offer mold protection, and can have increased thermal integrity over untreated SIPs due to lowered condensation and dew points. As illustrated by infrared flow and heat flow symbols 2310 and 2312, respectively, an untreated portion 2306 of a SIP 2302 can have a lower R-value than a portion 2308 treated with a SIP coating 2304.

In one embodiment, a SIP coating 2304 can have heat resistive properties whereby on a molecular level, conduction-connectivity pathways between surface layers of coating are prematurely terminated such that heat conduction is minimized. In another embodiment, a SIP coating 2304 can be a modified elastomer comprised of “near-2D” heat mirror “flakes”. When applied wet, the flakes randomly align, but upon drying the flakes can flatten to create a substantially common plane for reflection of radiant electromagnetic energy. In yet another embodiment, a SIP coating 2304 can comprise hollow vacuum-filled ceramic spheres operating as a resistive heat barrier. In other embodiments, a SIP coating 2304 can have any other known and/or convenient properties or characteristics.

FIG. 24

FIGS. 24 a-e depict embodiments showing elimination of a marriage wall compared to conventional construction. FIG. 24 a depicts a SIP structure constructed using typical construction techniques which result in marriage walls. A structure can be comprised of a plurality of modular units 2402. Each modular unit 2402 can be comprised of at least one exterior wall 2404 and at least one marriage wall 2406 that can be located on the interior of a structure when a modular unit 2402 is in position.

In conventional construction, at least two modular units 2402 can be positioned adjacent to each other such that a roof support section 2408 and a marriage wall 2406 on each modular unit 2402 can be proximal to each other. When roof support sections 2408 are in position to provide a structural support by applying lateral and shear forces on each other along the apex line of a roof, one or both marriage walls 2406, which can be held in place by support members 2410 can be removed.

FIG. 24 b depicts another technique in which a marriage wall 2406 can be offset with respect to a lateral interior edge of a roof support section 2408.

FIG. 24 c depicts another technique in which both marriage walls 2406 can be offset with respect to a lateral interior edge of a roof support section 2408 by using brackets 2412.

FIG. 25

FIGS. 25 a-i depict various details and embodiments of a temporary wall comprised of removable supports. FIGS. 25 c-f depict alternate construction techniques and structures that can permit elimination of the marriage walls in construction and result in a more efficient structure. While depicted as in use with SIP construction, similar and identical construction techniques can be implemented using other structural systems and elements.

In some embodiments, a support system can be comprised of a plurality of vertical support posts 2502, angle support assemblies 2504, top assemblies, bottom assemblies 2508, angled adaptors 2510, and adjustable angle plates 2512.

FIG. 25 a depicts a side view of an embodiment of a top assembly 2506 in an embodiment of the present device. A top assembly 2506 can be comprised of an inside vise pivot plate 2514, which on its exterior side can further comprise an integral “T” block 2516 for cradling pivot arms 2518. In some embodiments, close tolerance between a pivot arm 2518 and “T” block 2516 can add shear resistance to pivot bolts 2520. The vertical portion of the “T” can have at least one hole 2522, which, in some embodiments, can be threaded, for attaching added support members or any other known and/or convenient attachments to allow for any angle or plane of support. Holes 2522 in a pivot plate 2514 can allow for temporary fasteners to secure a plate 2514 while completing the top vise assembly 2506. Temporary fasteners can remain in place until modules are connected.

A pivot plate 2514 can have on its interior side, at its base, a gusset horizontal V-notched block 2524 that, in some embodiments, can extend approximately ¾″ from the plate face, or any other known and/or convenient length. A V-notched block 2524 can provide positive alignment while gaining added strength in the assembly. Above a V-block 2524 can be a smooth face on a pivot plate 2514 with pointed spikes 2526 that when the vise plates compress on a beam assembly the spikes penetrate into the wood beam further securing the clamp into position.

In some embodiments, pivot arms 2518 can be adjustable to a range of 0-90 degree, or any known and/or convenient range. Pivot arms 2518 can be made of machined or cast metal, polymer, or any other known and/or convenient material, and can have a rounded head to match close tolerance between arm head and plate “T”, or any other known and/or convenient geometry. A pivot arm 2518 can have a shoulder and extension 2528 to backstop and support tubing 2530. An extension 2528 can have coordinated holes with tubing 2530, which can be used for quick-lock pins 2532 to secure tubing 2530 to a pivot arm 2518. Quick-lock pins 2532 can allow for interchangeable tubing lengths.

FIG. 25 b depicts a front view of an embodiment of a top assembly 2506 in an embodiment of the present device.

FIG. 25 c depicts an angle support assembly 2504. An angle support assembly 2504 can comprise a telescoping pivot support 2534. Quick-lock pins 2536 can allow for interchangeable tubing lengths. Holes 2538 between inner 2540 and outer tubes 2542 can be coordinated and installed at regular intervals.

FIG. 25 d depicts a bottom assembly 2508. A bottom assembly 2508 can comprise a vise plate 2544, that can have a flat base 2546. A flat base 2546 can have a plurality of holes 2546 that can be coordinated for a variety of fasteners into underlying beam and joist configurations. A vise plate 2544 can have at least one v-block support 2548 on at least one side of a vise plate 2544.

In some embodiments, pivot arms 2550 can be adjustable to a range of 0-90 degrees, or any known and/or convenient range. Pivot arms 2550 can be made of machined or cast metal, polymer, or any other known and/or convenient material, and can have a rounded head to match close tolerance between arm head and plate “T”, or any other known and/or convenient geometry. A pivot arm 2550 can have a shoulder and extension 2552 to backstop and support tubing 2530. An extension 2552 can have coordinated holes with tubing 2554, which can be used for quick-lock pins 2532 to secure tubing 2530 to a pivot arm 2550.

FIG. 25 e depicts a variety of top and bottom assembly angled adaptors, and FIG. 25 f depicts adjustable angle plates, such as, but not limited to, kicker and strut plates, to accommodate any number of or any known and/or convenient bracing possibilities, horizontal or vertical. FIG. 25 g depicts one such adaptation.

FIG. 25 h depicts a vertical support post 2502. A vertical support post 2502 can further comprise a screw-jack device 2554, or any other known and/or convenient device. In embodiments having a screw jack device 2554, a handle 2556 or any other known and/or convenient device can provide an adjustment mechanism. A screw-jack device 2554 can further comprise a fine-adjustment mechanism 2558 and a coarse-adjustment mechanism 2560. A vertical support pose 2502 can further comprise a top member 2562 and a bottom member 2564 that can be configured to connect with a top assembly 2506. A top member 2562 and a bottom member 2564 can each have at least one hole 2566, which can be threaded, and can accommodate any known and/or convenient fastener.

FIG. 25 i depicts two possible system configurations. 

1. A method of construction comprising: pre-fabricating structural insulated panel modules such that said prefabricated structural insulated panel modules can be selectively coupled with minimal construction effort. 